Footwear having a flexible outsole

ABSTRACT

An article of footwear is constructed from an outsole to which there is attached an upper. The outsole is provided with an upstanding sidewall and adjoining lip which form an outwardly projecting edge. The outsole is attached to the outer surface of the lip adjacent the edge by stitching and/or adhesive bonding. The outsole defines a hollow interior for receiving footwear components such as lining material, an insole and the like.

CROSS-RELATED APPLICATIONS

[0001] The present application claims the benefit of U.S. provisionalapplication No. 60/347,570 filed Oct. 25, 2001, which is incorporatedherein by reference.

TECHNICAL FIELD

[0002] The present invention relates in general to the footwearindustry, and more particularly, to various forms of footwear such asshoes, boots, sneakers and the like having an upper secured to anoutsole.

BACKGROUND OF THE INVENTION

[0003] Footwear is constructed from a number of components of variousconstruction and design which are assembled to form the finishedproduct. Two components that are most universally found in footwear arean outsole and an upper. An outsole is broadly defined as the outer soleor bottom walking surface of the footwear. An outsole can be constructedfrom a variety of natural and synthetic materials, for example, leatherand polymers. The upper is broadly defined as that part of the footwearwhich is attached to and extends above the outsole. The upper can alsobe constructed from a variety of natural and synthetic materials, forexample, leather and polymers, as well as combinations thereof.

[0004] In a variation, the footwear may also include a midsole which isprovided on the outsole and to which the upper may be fully or partiallyattached. The midsole, like the outsole, can be constructed from avariety of materials. Typically, the outsole and the midsole will beformed of polymer materials having different properties of flexibility,resiliency and/or cushioning effect. In this regard, the outsole can beconstructed of a more rigid wear resistant polymer to accommodate theabrasive and functional requirements of an outsole. On the other hand,the midsole may be constructed as a more flexible or resilient materialto provide cushioning and shock absorbing properties for the wearer.

[0005] In constructing the footwear, the upper must be secured to theoutsole or midsole during the assembling process. There are knownvarious techniques by which the upper is attached to the outsole ormidsole, for example, using board lasting, slip lasting, stitch and turnand stitch down techniques. Each of these techniques have their ownadvantages and disadvantages which are known in the footwearconstruction industry.

[0006] In board lasting, which is the most common, a board material istacked onto a last which is a block of wood, metal or plastic shapedliked a person's foot on which the footwear are formed. The upper ispulled over the last using significant force and glued to the boardmaterial. The pattern of the upper is not required to be exact as anyexcess material is pulled over and attached to the board material. Inthe event a gap remains about the glued periphery of the upper over theboard material, the gap is filled in with felt material so that the userdoes not feel the void when walking. The felt material is often glued tothe board material. The upper undergoes a heating and cooling process tomold the upper to the shape of the last. In the final processing, theoutsole is glued to the bottom of the upper which is overlying the boardmaterial, as well as the felt material if present. In a variation, amidsole is first glued to the upper and board material, followed bygluing an outsole to the midsole. Subsequently, the last is removed fromthe completed footwear and subsequently checked for the removal of alltacks which could cause injury to the wearer.

[0007] Board lasting construction is generally extensive in that excessmaterial, for example leather, is required for the uppers so as toenable adhering to the board material. The use of glue, as well as therequirement for felt fillers, also adds to the construction expense andresulting purchase price of the footwear. In addition, the formation ofmultiple layers over the last, e.g., board material, upper material,felt material and glue decreases the flexibility of the outsole.

[0008] In stitch lasting, an upper is stitched around an insole which isconstructed from a soft flexible material. The resulting assembly isreferred to as a bootie. Due to the flexible nature of the bootie, thebootie can be slipped over the last without the need of excessive forceas required in board lasting construction. However, the bootie must bebased upon a precise pattern such that the bootie fits exactly to thelast both in size and shape. The construction of a bootie is faster andeasier than the aforementioned board lasting construction, but as noted,requires a precise pattern. Subsequently, the bootie supported by thelast undergoes a heating and cooling cycle until the desire shape of theupper is achieved. Finally, the outsole, or combination with midsole,are adhered to the bootie.

[0009] Slip lasting construction has a number of advantages. Forexample, there is no need for felt fillers and the use of less leatheras there is no wrapping of the upper over the board material. Theelimination of these components, as well as the glue layers, results inthe footwear being more flexible than those of board lastingconstruction.

[0010] In stitch and turn construction, the outsole is provided with aperipheral circumscribing edge whose surface is parallel to the topsurface of the outsole. A peripheral bottom edge of the upper is turnedinwardly and positioned over the upper surface of the circumscribingedge. The upper is adhered by stitching downwardly through the upperinto the surface of the edge around the perimeter of the outsole.Subsequently, the footwear is placed over a last and subjected to theheating and cooling cycle for shaping the footwear. In a similar processincorporating a midsole, the technique is referred to as stitch downconstruction.

[0011] Accordingly, there is known a variety of techniques formanufacturing footwear, each technique having its own advantages anddisadvantages. In general, resilient support and flexibility are ofparamount importance in the construction of footwear. These propertiesgreatly enhance and comfort and wearability of the footwear for the enduser. Although slip lasting and stitch and turn construction providegreater flexibility, vis-à-vis boarding lasting construction, theseconstructions possess the aforementioned disadvantages, for example, theneed for precise patterns for the upper.

[0012] There is therefore the need for further improvements in theconstruction of footwear which provides enhanced flexibility to theoutsole.

SUMMARY OF THE INVENTION

[0013] Footwear such as shoes, boots, sneakers and the like areconstructed to include an upper which is attached to an outsole. Theoutsole can be constructed from a variety of materials, and preferably,synthetic materials such as polymers suitable for functioning in anenvironment to which the article of footwear will be subjected by thewearer. The outsole further can be constructed in a variety of shapesand sizes to accommodate the various styles desired. The outsole inaccordance with one embodiment of the present invention includes afoot-shaped support having a top surface, a bottom surface and aperipheral edge. An upstanding sidewall circumscribes the peripheraledge of the support. An upstanding lip extends circumferentially aboutthe sidewall in the manner as an extension of the sidewall. The outersurface of the lip forms with the outer surface of the sidewall anoutwardly projecting edge circumscribing the sidewall and thefoot-shaped support. The outer surface of the lip is provided with asurface region adapted for securing a portion of an upper thereto suchas by stitching and/or adhesive bonding. The top surface of the support,the inner surfaces of the sidewall and lip form a hollow region sizedand shaped to receive a human foot upon completed construction of thefootwear.

[0014] In accordance with one embodiment of the present invention thereis described an article of footwear including an upper and an outsoleattached to the upper. The outsole includes a foot-shaped support havinga top surface, a bottom surface and a peripheral edge; an upstandingsidewall circumscribing the peripheral edge of the support, the sidewallhaving an inner surface and an outer surface; an upstanding lipextending circumferentially about the sidewall, the lip having an innersurface and an outer surface, the outer surface of the lip forming withthe outer surface of the sidewall an outwardly projecting edgecircumscribing the sidewall, the top surface of the support, the innersurface of the sidewall and the inner surface of the lip forming ahollow region adapted for receiving a human foot; the upper attached tothe outer surface of the lip adjacent the outwardly projecting edge.

[0015] In accordance with another embodiment of the present inventionthere is described an outsole for an article of footwear. The outsoleincludes a foot-shaped support having a top surface, a bottom surfaceand a peripheral edge; an upstanding sidewall circumscribing theperipheral edge of the support, the sidewall having an inner surface andan outer surface; an upstanding lip extending circumferentially aboutthe sidewall, the lip having an inner surface and an outer surface, theouter surface of the lip forming with the outer surface of the sidewallan outwardly projecting edge circumscribing the sidewall, the outersurface of the lip adapted for securing a portion of an upper thereto;and the top surface of the support, the inner surface of the sidewalland the inner surface of the lip forming a hollow region adapted forreceiving a human foot.

[0016] In accordance with another embodiment of the invention there isdescribed an outsole for an article of footwear, the outsole comprisinga foot-shaped support having a top surface, a bottom surface and aperipheral edge; an upstanding member extending circumferentially aboutthe support adjacent the peripheral edge, the member having an innersurface and an outer surface, the member providing an outwardlyprojecting edge adjacent said peripheral edge circumscribing thesupport, the outer surface of the member adapted for securing a portionof an upper thereto; and the top surface of the support and the innersurface of the member forming a hollow region adapted for receiving ahuman foot.

[0017] In accordance with another embodiment of the invention there isdescribed an article of footwear comprising an upper; and an outsoleattached to the upper; the outsole comprising a foot-shaped supporthaving a top surface, a bottom surface and a peripheral edge, anupstanding member extending circumferentially about the support adjacentthe peripheral edge, the member having an inner surface and an outersurface, the member providing an outwardly projecting edge adjacent saidperipheral edge circumscribing the support, the top surface of thesupport and the inner surface of the member forming a hollow regionadapted for receiving a human foot, the upper attached to the outersurface of the member adjacent the outwardly projecting edge.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The above description, as well as further objects, features andadvantages of the present invention will be more fully understood withreference to the following detailed description of a footwear having aflexible outsole, when taken in conjunction with the accompanyingdrawings wherein:

[0019]FIG. 1 is a side elevational view of an article of footwearconstructed in accordance with one embodiment of the present invention;

[0020]FIG. 2 is a side elevational view of an outsole constructed inaccordance with one embodiment of the present invention as shown in FIG.1;

[0021]FIG. 3 is a top plan view of the outsole as shown in FIG. 2;

[0022]FIG. 4 is a front elevational view of the outsole as shown in FIG.2;

[0023]FIG. 5 is a cross-sectional view taken longitudinally through thearticle of footwear as shown in FIG. 1 in accordance with one embodimentof the present invention;

[0024]FIG. 6 is a cross-sectional view taken longitudinally through thearticle of footwear as shown in FIG. 1 in accordance with anotherembodiment of the present invention;

[0025]FIG. 7 is a side elevational view of an article of footwearconstructed in accordance with another embodiment of the presentinvention;

[0026]FIG. 8 is a cross-sectional view taken longitudinally through thearticle of footwear as shown in FIG. 7 in accordance with anotherembodiment of the present invention;

[0027]FIG. 9 is a side elevational view of an upper having an innerlining supported on a last during the manufacturing process; and

[0028]FIG. 10 is a diagrammatic illustration of a sewing machine withsewing arm adapted for stitching an upper to an outsole in accordancewith the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] In describing the preferred embodiments of the subject matterillustrated and to be described with respect to the drawings, specificterminology will be resorted to for the sake of clarity. However, theinvention is not intended to be limited to the specific terms soselected, and is to be understood that each specific term includes alltechnical equivalence which operate in a similar manner to accomplish asimilar purpose.

[0030] Referring now to the drawings, where like reference numeralsrepresent like elements, there is shown in FIG. 1 an article of footwearin the nature of an infant's sneaker designated generally by referencenumeral 100. The invention in accordance with one embodiment will bedescribed with reference to the sneaker 100. It is to be understood thatthe invention is equally applicable to other forms of footwear otherthan the sneaker 100 as shown. For example, the present invention issuitable for incorporation in all forms of footwear, for example, adultsneakers, jogging shoes, tennis shoes, boots, work boots, casual shoes,dress shoes and the like. In general, the present invention is adaptedfor use in any article of footwear in which an upper is to be attachedto an outsole.

[0031] In this regard, and as shown in FIG. 1, the sneaker 100 willoften include a variety of components, and specifically, includes anupper 102 and an outsole 104. The upper 102 and outsole 104 define theshape and style of the sneaker 100. The upper 102 and outsole 104 can beconstructed from a variety of natural and synthetic materials, as wellas composites thereof. For example, the upper 102 is often formed fromleather, or a combination of leather and man-made polymer materials suchas nylon, polyurethane, polyester and mesh. The upper may be formed in avariety of colors and surface finishes such as brushed leather, smooth,weaved, mesh, pattern embossed, etc. The upper 102 may be formed withvarious devices for closing the footwear opening such as laced eyelets106, clips, elastomeric materials and the like. In designing thefootwear such as the sneaker 100, it is to be understood that aninfinite variety of shapes, sizes, materials and designs may beincorporated into the finished footwear embodying the present invention.

[0032] The outsole 104 is preferably formed from a synthetic polymer,however, it is contemplated that natural materials such as leather canalso incorporate the present invention. In the case of polymers,suitable polymers include, by way of example and not by limitation,thermoplastic rubber, rubber, polyurethane, thermoplastic polyurethaneand polyvinyl chloride. It is also contemplated that the outsole 104 maybe formed from combinations of polymers having different properties of,for example, mechanical strength, resiliency, wear resistance, rigidity,cushioning effect and the like. Thus, various portions of the outsole104 may be molded from one type of polymer material, and another portionof the outsole co-molded with another polymer material having differentphysical characteristics. Thus, the outsole 104 can be tailored toprovide varying degrees of mechanical properties at different portionsof the outsole as may be desired depending upon the intended wearer andfunction of the footwear. For purposes of simplifying the explanation ofthe present invention, the upper 102 will be described as beingconstructed from leather, and the outsole 104 constructed from polymermaterial.

[0033] Referring to FIGS. 2-4, there will be described the constructionof the outsole 104 in accordance with one embodiment of the presentinvention. As shown, the outsole 104 is generally molded as an intervalone piece outsole using any suitable molding or polymer castingtechnique. The outsole 104 is provided with a bottom member 107 having abottom surface 108 which engages a supporting surface, such as a floorwhen wearing the sneaker 100. To this end, the bottom surface 108 may beprovided with ribs 110, which in addition to providing traction, alsoincreases the flexibility of the outsole 104 by providing transversechannels 112 of reduced polymer thickness within the bottom member 107.In particular, the channels 112 could be formed at a location along thebottom surface 108 where the outsole 104 would typically bend duringflexing of a person's foot while walking or running. However, it is tobe understood that the formation of ribs 110 and/or channels 112 are notrequired pursuant to the present invention.

[0034] The outsole 104 is formed with a circumscribing upstandingsidewall 114 which is integral with the bottom member 107. The sidewall114 may be of various heights and profiles such as including arcuateportions to define the style and aesthetics of the sneaker 100. As shownin FIG. 2, the sidewall 114 is undulating having a high portion 116 inthe region of the sneaker's arch support. It is to be understood thatthe sidewall 114 may be of any shape, generally having a height in therange of 5 to 25 mm, although other heights greater and less arecontemplated in accordance with the present invention.

[0035] The sidewall 114 merges with a circumscribing upstanding lip 118which is integrally formed therewith during the manufacturing process ofthe outsole 104. The lip 118 is provided with an outer surface which isinwardly offset from the outer surface of sidewall 114 to provide acircumscribing edge 120. On the other hand, the inner surface of thesidewall 114 is often flush with the inner surface of the lip 118. Thelip 118 typically follows the contour of the sidewall 114 as best shownin FIG. 2. As will be explained in detail hereinafter, the upper 102 isattached to the outer surface of the lip 118 by any suitable means suchas adhesives, stitching and the like.

[0036] In general, it is contemplated that the edge 120 will have awidth approximately corresponding to the thickness of the upper 102.This will result in the outer surface of the upper being flush with theouter surface of sidewall 114. By way of example, uppers have athickness in the range of 1 to 2 mm, and preferably about 1.6 mm. It isalso contemplated that the width of the edge 120 may be greater or lessthan the thickness of the upper 102 providing the sneaker 100 with aparticular aesthetic design feature if so desired.

[0037] The lip 118 has sufficient width for supporting the lower edge ofthe upper 102 and for securing same thereat. The upper 102 can beattached directly to the lip 118 by any suitable means, for example, bystitching, stapling, adhesive bonding and the like. Suitable adhesivesinclude glue, cement, thermo-set adhesives, hot melt adhesives,thermoplastic adhesives and the like. In general, a lip 118 having awidth of about 6 mm is suitable for practicing the present invention.However, it is contemplated that a lip 118 having a width in the rangeof about 2 to 15 mm may also be used. The outer surface of the lip 118and edge 120 form a receiving space to accommodate the lower portion ofthe upper 102.

[0038] The lip 118 may be of uniform thickness across its width, ortapered to reduced thickness circumferentially about its upper edge 122.By tapering the lip 118, this provides the lip with greater flexibilityas well as providing less bulk material along the sides of the wearer'sfoot to increase wearing comfort. By way of example, the lip 118adjacent edge 120 may have a thickness in the range of 1 to 12 mm, andpreferably about 5 mm. As noted, the upper edge 122 may be feathered ortapered to a substantially thinner dimension if desired.

[0039] As shown in FIG. 4, the front edge of the lip 118 is providedwith a notch 124 which is shown as V-shaped. However, the notch 124 maybe U-shaped, rectangular, circular and the like. In addition, the lip118 may be provided with a plurality of notches about the forward edgeof the lip 118. The notch or notches 124 provide the ability of theupper portion of the lip 118 to conform to the curved shaped of theupper 102 without bunching up. In this regard, as shown in FIG. 1, theupper 102 at its forward portion 126 curves inwardly to define a regionof reduced circumference. The notch 124 allows the lip 118 to conform tothe shape of the forward portion 126 within the region of reducedcircumference without bunching up. The notch 124 is therefore to beunderstood as an optional feature of the outsole 104 and not essentialto the practicing of the present invention. In this regard, based uponthe design of the footwear and size of the lip 118, the aforementionedconsiderations may not be present.

[0040] As best shown in FIG. 5, the outsole 102 is formed to include alarge hollow region or cavity 128 which extends throughout the interiorof the outsole 104, e.g., bound by the interior surfaces of the sidewall114, lip 118 and top surface 130 of the bottom member 107. The hollowregion 128 is sized and shaped to receive the remaining components ofthe sneaker 100 as to be described, as well as the wearer's foot in acomfortable and shape conforming manner.

[0041] In accordance with one embodiment as shown in FIG. 5, the upper102 is attached circumferentially about lip 118 of the outsole 104adjacent ledge 120. The attachment may be accomplished by any suitablemethod, for example, stitching, adhesive bonding and/or combinationsthereof. When a stitching technique is incorporated, it is generallypreferred that the stitch line be proximate the edge 120 of the outsole104. This prevents potential flaring of the bottom edge of the upper 102away from the lip 118. It is to be understood that multiple stitch linesmay be used to secure the upper 102 to the outsole 102. Once the upper102 has been attached to the outsole 104, a last is placed into thehollow region 128 to mold the upper 102 into the desired shape of thefootwear during the subsequent heating and cooling process.

[0042] In completing the construction of the sneaker 100, an insole 132of various materials may be placed overlying the top surface 130 of thebottom member 107 of the outsole 104. The insole 132 may be freelyremovable or adhered using a suitable adhesive. The insole 132 can beformed from a variety of natural and synthetic materials, as well ascombinations thereof. In the preferred embodiment, the insole 132 willbe formed of a synthetic material which provides shock absorbing andcushioning properties to aid in the comfort for the wearer. By way ofexample, suitable materials for the insole include ethyl vinyl acetate(EVA), polyurethane and thermoplastic polyurethane. The insole 132 alsoprovides a smooth supporting surface for the wearer's foot therebycovering any irregularities in the top surface 130 of the bottom member107.

[0043] In accordance with the preferred embodiment, the upper 102 isattached to the outsole 104 in the manner as shown in FIG. 6. The upper102 is initially provided with an inner lining 134. The inner lining 134is adhered to the inner surface of the upper 102 by any suitable means,for example, by stitching around an upper peripheral edge, by adhesivebonding and/or the like. The inner lining 134 may be constructed from avariety of natural and synthetic materials to provide comfort to thewearer, for example, to provide a soft, comfortable surface against thewearer's foot.

[0044] As shown in FIG. 6, it is preferred that the lining extend beyondthe length or bottom of the upper 102. In this regard, the inner lining134 will extend beyond the location of edge 120 of the outsole 104 to alocation proximate the top surface 130 of the bottom member 107. Thebottom edge 136 of the inner lining 134 is attached to a second layer oflining material 138. The lining material 138 may be the same or of adifferent composition from the inner lining 134. For example, the innerlining 134 may be constructed from leather material, while the liningmaterial 138 may be constructed from synthetic material. The innerlining 134 is attached to the edges of the lining material 138 by anysuitable means, for example, by peripherally stitching along the bottomedge 136 and/or the use of adhesives. The resulting combination producesa bootie having a closed end by virtue of the lining material 138. As inslip lasting construction, the bootie requires that its pattern conformclosely to the shape and size of the last which is being used in theconstruction process.

[0045] The lining material 138 is positioned on the top surface 130 ofthe bottom member 107 with the inner lining 134 extending upwardly overthe inner surface of sidewall 114 and lip 118, and the upper 102extending over the outer surface of the lip terminating adjacent andoverlying edge 120. As shown, the lip 118 is captured between the innerlining 134 and lower portion of the upper 102. In the manner aspreviously described, the lower portion of the upper 102 is stitched,adhesive bonded or other ways secured to the lip 118 adjacent edge 120.It is not a requirement that the inner lining 134 be adhered to the lip118. The lining material 138 is preferably adhered to the top surface130 of the bottom member 107 using a suitable adhesive.

[0046] The upper 102 is sized and shaped by placing a last into thehollow region 128 and subjecting the assembly to a heating and coolingprocess. An insole 132 may be placed into the hollow region 128overlying the lining material 138 to provide resilient cushioning andshock absorbing properties as previously described.

[0047] Based upon the foregoing construction of the sneaker 100 or otherarticle of footwear in accordance with the present invention, thesneaker is provided with enhanced flexibility in the outsole 104. Inaddition, the presence of the hollow region 128 allows for the use of acushioning resilient insole 132 which can have varying characteristicsdepending upon the footwear's application, e.g., jogging shoes, workboots, etc. Thus, the outsole 104 of the present invention does notrequire the incorporation of a midsole to provide the cushioning effectof the prior constructions. The desired cushioning effect is achieved bythe use of an insole 132 which can be tailored to provide the desiredeffect by selecting the materials of construction and thickness of theinsole. The construction of an article of footwear in accordance withthe present invention provides a great degree of latitude in designedfeatures to provide an article of footwear which is flexible whileaccommodating various footwear components such as linings and insoles.

[0048] Referring to FIG. 7, there is shown a work boot 140 constructedin accordance with the present invention. The work boot 140 includes anupper 142 and an outsole 144. The upper 142 may be constructed in asimilar manner to the upper 102 as previously described. Similarly, theoutsole 144 may be constructed in a similar manner to the outsole 104 aspreviously described. However, variations in the outsole 144, bothcosmetic and functional, may be incorporated into the outsole design. Asshown by way of one example, the outsole 144 is provided with a raisedheel 146 which may include an inner hollowed out region 148 whichreduces the mass of material of the outsole 144 thereby providinggreater flexibility in the heel region.

[0049] A peripherally circumscribing lip 150, as best shown in FIG. 8,is provided with an outwardly protruding edge 152 adjacent the sidewall114 as similarly described with respect to lip 118 and edge 120. Thesidewall 114 is of a lesser height than the sidewall shown in theembodiment described in FIG. 5. This provides the work boot 140 with adifferent look than the sneaker 100. It is to be understood that the lip150 can extend upwardly directly from the top surface 107 of the bottommember 130. In this regard, the edge 120 would be formed by theprotruding portion of the top surface 130 of the bottom member 107.

[0050] The lip 150 and sidewall 114 may be integrally formed, forexample, by molding with the bottom member 107 of the outsole 144. Thelip 150 and sidewall 114 can be constructed from the same or similarmaterial as the remaining portion of the outsole 144. However, the lip150 and sidewall 114 can be constructed by co-molding two differentpolymer materials having different characteristics, one for the lip andsidewall and one for the bottom member 107. In this regard, the bottommember 107 can be constructed of a wear resistant flexible material,while the sidewall 114 and lip 150 may be constructed of a stiffermaterial to which the upper 142 is to be attached. Accordingly, by usinga variety of natural and/or polymer materials, various characteristicsof the outsole 144 can be achieved, for example, flexibility,resiliency, wear resistance, etc.

[0051] As further shown in FIG. 8, the outsole 144 is provided with ahollow region 128 which is designed to receive the bootie formed fromthe assembly of upper 142, inner lining 134 and lining material 138. Theresulting bootie is attached to the outsole 144 via the lip 150 aspreviously described with respect to the bootie illustrated in FIG. 6.In the event the heel 146 is provided with a hollowed out region 148, itcan be filled with similar material to the lining material 138. Thisprovides a smooth, flat surface 107 for supporting the insole 132. Oncethe bootie via the upper 142 is attached to the outsole 144, theassembly is processed as thus far described by inserting a last into thebootie and conforming the upper 142 to the last shape by a heating andcooling process. Accordingly, it can be appreciated that a variety ofstyles and designs of an article of footwear can be constructedincorporating the principles of the present invention as thus fardescribed and equivalence thereof.

[0052] Referring to FIG. 9, an upper 102 having an inner lining 134 isshown stretched over a last 153 in the shape of the finished footwear,the outsole 104 being shown in phantom. The bottom portion of the last153 extends downwardly into the hollow region 128 and is supported ontop surface 130 of the outsole 104. In this regard, the last 153 extendsoutwardly beyond the bottom edge of the upper 102. This extended portionof the last 153 is received within the hollow region 128 of the outsole104. Accordingly, the last 153 drops into the outsole 104, as opposed tobeing supported onto the top surface of the outsole as is known from theprior footwear constructions. By having the last 153 extending into thehollow region 128 of the outsole 104, the upper 102 which begins at thebottom of the last essentially starts within the outsole 104 at the topsurface 130. This construction allows the upper 102 to have a lowerheight than previously known constructions. That is, in accordance withthe prior footwear as previously noted, the top of the outsole issupported directly on the bottom of the last 153 thereby increasing theheight of the upper 102. Having an upper 102 of a lower profile providesan enhanced aesthetic appeal to the article of footwear.

[0053] This construction, as previously noted, also provides a regionfor receiving an insole 132. In the prior footwear constructions, theinsole which is supported on the outsole, occupies a portion of theinterior of the upper where a person's foot would be received. In orderto accommodate the thickness of the insole, it is generally requiredthat the upper be increased in height to provide additional volume. Thisincreased height can detract from the aesthetics of the footwear. Byproviding a hollow region 128 within the outsole 104, the hollow regioncan accommodate an insole 132 of varying thicknesses without thenecessity of increasing the height of the upper 102.

[0054] As previously described, the upper 102, 142 can be attached tothe lip 118, 150 by means of stitching. This can be accomplished using asewing machine of the type used in the footwear industry, such as in themanufacture of footwear of slip lasting and stitch and turnconstruction. As shown in FIG. 10, a sewing machine adapted for thestitching process is shown generally in diagrammatic illustration andidentified by reference numeral 154. The sewing machine 154 includes ahead 156 adapted for reciprocal motion of an attached needle 158 toperform the stitching operation. The head 156 should be of minimum sizeso as to not interfere with the turning of the article of footwearduring the stitching process. As is conventional in a sewing machine,the head 156 reciprocates while removably securing the needle 158thereto during the stitching process.

[0055] The sewing machine 154 generally requires a backing plate whichsupports the article to be stitched underlying the reciprocating head156. Known sewing machines are provided with a stationary, fixed backingplate. This construction of a sewing machine makes it difficult toperform the stitching operation for securing the upper 102, 142 to theoutsole 104, 144. Accordingly, a conventional sewing machine can bemodified whereby the conventional backing plate is replaced with a swingarm 160 which is pivotably attached to the sewing machine base 161. Theswing arm 160 is provided with a backing plate 162 which can bepositioned underlying the needle 158 or rotated away from the needle asmay be required to initiate the stitching process.

[0056] More specifically, the swing arm 160 is initially swung away fromunder the needle 158 to provide clear access to the backing plate 162.The backing plate 162 is sized and shaped to be received within thehollow region 128 of the article of footwear underlying the region wherethe stitching process is to be performed. In accordance with the presentinvention as thus far described, this region is generally underlying thelip 118, 150 adjacent edge 120. The swing arm 160 is returned to itsoperative position in alignment underlying the needle 158. During thestitching process, the article of footwear is turned about the backingplate 162 to enable stitching of the upper 102, 142 to the lip 118, 150as the article of footwear is turned about the backing plate 162. Thebacking plate 162 is accordingly sized in relationship to the hollowregion 128 to allow turning of the article of footwear 360° about thebacking plate during the stitching process.

[0057] Although the present invention has been described with respect tothe use of a particular sewing machine 154, it is to be understood thatother designs of a sewing machine may be used to effect the stitching ofthe upper to the outsole. In addition, where an adhesive is used, anyform of adhesive applicator known in the footwear industry may be used.Accordingly, it is to be understood that the present invention is not tobe limited in any respect as to the manner of stitching, adhesivebonding, or otherwise adhering the upper to the outsole.

[0058] Although the invention herein has been described with referenceto particular embodiments, it is to be understood that these embodimentsare merely illustrative of the principles and applications of thepresent invention. It is therefore to be understood that numerousmodifications may be made to the illustrative embodiments and that otherarrangements may be devised without departing from the spirit and scopeof the present invention as defined by the appended claims.

1. An outsole for an article of footwear, said outsole comprising afoot-shaped support having a top surface, a bottom surface and aperipheral edge; an upstanding member extending circumferentially aboutsaid support adjacent said peripheral edge, said member having an innersurface and an outer surface, said member providing an outwardlyprojecting edge adjacent said peripheral edge circumscribing saidsupport, said outer surface of said member adapted for securing aportion of an upper thereto; and said top surface of said support andsaid inner surface of said member forming a hollow region adapted forreceiving a human foot.
 2. The outsole of claim 1, wherein saidprojecting edge is formed by a portion of said top surface of saidsupport adjacent said peripheral edge and an adjacent portion of saidouter surface of said member.
 3. The outsole of claim 1, wherein saidprojecting edge has a width no less than about a width of an edgeportion of an upper adapted to be secured to said member.
 4. The outsoleof claim 1, wherein said member has a front edge provided with at leastone notch therein.
 5. The outsole of claim 1, wherein said member has anupper portion which is tapered in cross-section and a lower portion ofuniform cross-section.
 6. The outsole of claim 1, wherein said membercomprises an upstanding sidewall circumscribing said peripheral edge ofsaid support, said sidewall having an inner surface and an outersurface; and an upstanding lip extending circumferentially about saidsidewall, said lip having an inner surface and an outer surface, saidouter surface of said lip forming with said outer surface of saidsidewall said projecting edge circumscribing said sidewall, said outersurface of said lip adapted for securing a portion of an upper thereto.7. The outsole of claim 6, wherein said projecting edge has a width noless than about a width of an edge portion of an upper adapted to besecured to said lip.
 8. The outsole of claim 6, wherein said sidewallhas a uniform cross-section.
 9. The outsole of claim 6, wherein said liphas a tapered cross-section.
 10. The outsole of claim 6, wherein saidinner surface of said sidewall is flush with said inner surface of saidlip.
 11. The outsole of claim 6, wherein said sidewall and said lip areformed as an integral piece.
 12. The outsole of claim 6, wherein saidprojecting edge is spaced above said top surface of said support. 13.The outsole of claim 6, wherein said lip has a front edge provided withat least one notch therein.
 14. An outsole for an article of footwear,said outsole comprising a foot-shaped support having a top surface, abottom surface and a peripheral edge; an upstanding sidewallcircumscribing said peripheral edge of said support, said sidewallhaving an inner surface and an outer surface; an upstanding lipextending circumferentially about said sidewall, said lip having aninner surface and an outer surface, said outer surface of said lipforming with said outer surface of said sidewall an outwardly projectingedge circumscribing said sidewall, said outer surface of said lipadapted for securing a portion of an upper thereto; and said top surfaceof said support, said inner surface of said sidewall and said innersurface of said lip forming a hollow region adapted for receiving ahuman foot.
 15. The outsole of claim 14, wherein said projecting edgehas a width no less than about a width of an edge portion of an upperadapted to be secured to said lip.
 16. The outsole of claim 14, whereinsaid sidewall has a uniform cross-section.
 17. The outsole of claim 16,wherein said lip has a tapered cross-section.
 18. The outsole of claim16, wherein said inner surface of said sidewall is flush with said innersurface of said lip.
 19. The outsole of claim 16, wherein said sidewalland said lip are formed as an integral piece.
 20. The outsole of claim14, wherein said lip has a front edge provided with at least one notchtherein.
 21. An article of footwear comprising an upper; and an outsoleattached to said upper; said outsole comprising a foot-shaped supporthaving a top surface, a bottom surface and a peripheral edge, anupstanding sidewall circumscribing said peripheral edge of said support,said sidewall having an inner surface and an outer surface, anupstanding lip extending circumferentially about said sidewall, said liphaving an inner surface and an outer surface, said outer surface of saidlip forming with said outer surface of said sidewall an outwardlyprojecting edge circumscribing said sidewall, said top surface of saidsupport, said inner surface of said sidewall and said inner surface ofsaid lip forming a hollow region adapted for receiving a human foot,said upper attached to said outer surface of said lip adjacent saidoutwardly projecting edge.
 22. The article of claim 21, wherein saidprojecting edge has a width no less than about a width of an edgeportion of said upper.
 23. The article of claim 21, wherein saidsidewall has a uniform cross-section.
 24. The article of claim 21,wherein said lip has a tapered cross-section.
 25. The article of claim21, wherein said inner surface of said sidewall is flush with said innersurface of said lip.
 26. The article of claim 21, wherein said sidewalland said lip are formed as an integral piece.
 27. The article of claim21, wherein said projecting edge is spaced above said top surface ofsaid support.
 28. The article of claim 21, wherein said lip has a frontedge provided with at least one notch therein.
 29. An article offootwear comprising an upper; and an outsole attached to said upper;said outsole comprising a foot-shaped support having a top surface, abottom surface and a peripheral edge, an upstanding member extendingcircumferentially about said support adjacent said peripheral edge, saidmember having an inner surface and an outer surface, said memberproviding an outwardly projecting edge adjacent said peripheral edgecircumscribing said support, said top surface of said support and saidinner surface of said member forming a hollow region adapted forreceiving a human foot, said upper attached to said outer surface ofsaid member adjacent said outwardly projecting edge.
 30. The article ofclaim 29, wherein said projecting edge is formed by a portion of saidtop surface of said support adjacent said peripheral edge and anadjacent portion of said outer surface of said member.
 31. The articleof claim 29, wherein said projecting edge has a width no less than abouta width of an edge portion of an upper adapted to be secured to saidmember.
 32. The article of claim 29, wherein said member has a frontedge provided with at least one notch therein.
 33. The article of claim29, wherein said member has an upper portion which is tapered incross-section and a lower portion of uniform cross-section.
 34. Thearticle of claim 29, wherein said member comprises an upstandingsidewall circumscribing said peripheral edge of said support, saidsidewall having an inner surface and an outer surface; and an upstandinglip extending circumferentially about said sidewall, said lip having aninner surface and an outer surface, said outer surface of said lipforming with said outer surface of said sidewall said projecting edgecircumscribing said sidewall, said outer surface of said lip adapted forsecuring a portion of an upper thereto.
 35. The article of claim 34,wherein said projecting edge has a width no less than about a width ofan edge portion of an upper adapted to be secured to said lip.
 36. Thearticle of claim 34, wherein said sidewall has a uniform cross-section.37. The article of claim 36, wherein said lip has a taperedcross-section.
 38. The article of claim 36, wherein said inner surfaceof said sidewall is flush with said inner surface of said lip.
 39. Thearticle of claim 36, wherein said sidewall and said lip are formed as anintegral piece.
 40. The article of claim 34, wherein said lip has afront edge provided with at least one notch therein.